Challenge: Nanofibers are constantly drawing the attention of material scientists and engineers as their surface-to-used-material-ratio is beneficial for, e.g., medical applications. However, technical nanofiber processing, transportation or even simple things as spooling is inhibited by their attraction to any surface by van der Waals forces, the adhesive forces also enabling geckos to stick to the wall. Recent research aims for scale-up of the controllable production of nanofibers though have not enabled an easier handling and thus their application is still limited. A specific kind of nanofibers are nanofibrous protrusions of adherent cells and microorganisms. The interaction of these fibers with nanostructures is a key feature for their controlled adhesion at natural or artificial surfaces. Inspiration by nature: One major problem for handling of nanofibers is their stickiness to almost any surface due to van der Waals forces. However, there is a biological example to show how to tackle this problem in the future: cribellate spiders bear a specialized comb, the calamistrum, to handle and process nanofibers, which are assembled to their structural complex capture threads. These 10 – 30 nm thick fibers do not stick to the calamistrum due to a special fingerprint-like nanostructure. This structure causes the nanofibers to not smoothly adapt to the surface of the calamistrum, but rather minimizes contact and thus reduce the adhesive forces between the nanofibers and the calamistrum. Radically new technological approach: The transfer of these bionic comb structures to a technical surface will enable that future tools for nanofiber handling (covered with such a nanostructure) are antiadhesive towards nanofibers. Similar nanostructures can hinder the adhesion of nanofibrous protrusions of cells or microorganisms, which may enable cell-repellent or antiseptic areas on medical devices and implants.

The objective of HIGHLANDER is to develop membrane electrode assemblies (MEAs) for Heavy-Duty Vehicles (HDV) with disruptive, novel components, targeting stack cost and size, durability, and fuel efficiency. The project will design, fabricate, and validate the HDV MEAs at cell and short stack level against heavy-duty relevant accelerated stress test and load profile test protocols. The unique approach of HIGHLANDER is to develop core fuel cell components in tandem, ensuring their greatest compatibility and lowest interface resistance: ionomer and reinforcement, catalyst and catalyst support, catalyst layer composition and property gradient in tune with the bipolar plate flow-field geometry. Materials screening efforts will be supported by the development and use of improved predictive degradation models bridging scales from reaction sites to cell level. Model parameterisation is implemented using experimental characterisation data at materials, component, and cell level. HIGHLANDER brings together a European supply chain of fuel cell materials and components producers and an OEM stack developer that makes this approach possible. HIGHLANDER aims to bring about a significant reduction in stack cost and fuel consumption through improvement of catalyst coated membrane performance and development of a new, lower cost single-layer gas diffusion layer. It will aim to achieve the 1.2 W/cm² at 0.65 V performance target at 0.3 g Pt/kW or below, meeting a lifetime target of 20,000 h. Sustainability considerations include benchmarking of fluorine-free membranes for HDV MEA application and re-use of platinum in the context of a circular economy.

GAIA has the overall aim of developing high power and high current density automotive MEAs well beyond the current state of the art up to TRL5. This project, encompassing OEMs, leading industrial and academic/research organisation/research institute partners with long expertise in fuel cell science and technology, and building on best developments from the FCHJU, will not only provide significantly higher performance MEAs but will also ensure the designs satisfy the cost, durability and operational targets set by the call. Accordingly, the specific objectives of the project are to: - Develop world-leading components (electrocatalysts, membranes, gas diffusion and microporous layers) and improve the interfaces between them to minimise resistances; - Realise the potential of these components in next generation MEAs showing a step-change in performance that will largely surpass the state of the art by delivering a beginning of life power density of 1.8 W/cm2 at 0.6 V; - Validate the MEA performance and durability in full size cell short stacks, with durability tests of 1000 h with extrapolation to 6,000 h; - Provide a cost assessment study that demonstrates that the MEAs can achieve the cost target of 6 €/kW for an annual production rate of 1 million square metres.